City University of Hong Kong

Division of Building Science and Technology

Associate of Science in Building Services Engineering

BST20532 HVAC Services 2

COMPRESSORS

AIMS & OBJECTIVES

After studying this lecture notes, students are expected to:
• understand the compressor as one of the essential components in a refrigeration system;
• distinguish the two main categories of compressor: positive displacement and non-positive displacement;
• understand the characteristics and configurations of different types of compressors, including the
reciprocating, rotary vane, screw, scroll and centrifugal compressors;
• determine the performance of a compressor, especially according to volumetric efficiency and compressor
efficiency.

OUTLINE
1. Positive Displacement Compressors
1.1 Reciprocating Compressors
1.2 Rotary Vane Compressors
1.3 Screw Compressors
1.4 Scroll Compressors

2. Non-positive Displacement Compressors - Centrifugal

2.1 Characterisitcs of Centrifugal Compressor
2.2 Advantages of Centrifugal Machines
2.3 Comparison of Different Compressors

3. Performance
3.1 Volumetric Efficiency
3.2 Compressor Efficiency

Tutorial
BST20532 HVAC Services 2 - Compressors

Compressors

Compressor is one of the important parts of the compression refrigeration system and serves
both to provide the necessary increase in pressure of refrigerant vapour and as a refrigerant
pump to circulate the refrigerant through the system in a continuous cycle. Refrigeration
compressors can be divided broadly into two categories:
• Positive displacement compressors
• Non-positive displacement compressors or dynamic compressors

1. Positive Displacement Compressors

The increase in pressure is by reducing the internal volume of the compression

chamber through work applied to the compressor’s mechanism. In vapour
compression refrigeration systems, the major types of positive displacement
compressors includes reciprocating, rolling piston, rotary vane, single screw, double
screw, and scroll.

1.1 Reciprocating Compressors

Most reciprocating compressors are single acting, using pistons drive directly through
a pin and connecting rod from the crankshaft. Double acting compressors are not
extensively used.

(a) Intake stoke (b) Compression and discharge stoke

Figure 1 Semi-hermetic Reciprocating Compressor

1.1.1 Drive and Motor Arrangement

The halocarbon compressor is the most widely used and is manufactured in 3 designs
according to the motor and drive arrangement: open, hermetic and semi-hermetic.
Ammonia compressors are manufactured only in the open design, in which the
driveshaft extends through a seal in the crankcase for an external drive.

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1.1.1.1 Open compressor

The crankshaft extends through the compressor housing so that a motor can be
externally coupled to the shaft. A seal is therefore required at the compressor housing
to prevent leakage (i.e. either refrigerant gas leaking out of, or ambient air leaking
into the compressor).

1.1.1.2 Hermetic compressor or welded-shell hermetic

The motor and the compressor are enclosed in the same pressure vessel; the motor
shaft is integral with the compressor crankshaft, and the motor is in contact with the
refrigerant. In many designs, cold suction gas is drawn across the motor to keep it
cool. Since moisture can damage the motor, dehydration of the hermetic units before
refrigerant charging (filling) is essential.

1.1.1.3 Semi-hermetic compressor or bolted hermetic

The compressor cylinder heads are removable so that the cylinder valves and pistons
can be readily serviced.

Hermetic Semi-hermetic Open

Initial Cost Low Average High
Leakage Minimum Average Shaft seal is
required
Maintenance Not accessible for Can be repaired Accessible
repair
Efficiency Average Average Higher

1.1.2 Key features of reciprocating compressors include:

- Size: range from fractional to hundred kW refrigeration capacities due to
limitation on compression ratio.
- Speed: range from 2 to 60 revolutions per second (120 to 3600 rpm).
- Single or multi-cylinder(s).
- Ammonia (R717), R22, R500, R502 & R134a can be used.
- Larger capacity chiller up to 500TR with 2 or more compressors / multi-cylinder.
- Capacity control by on/off mode, variable speed motor, cylinder unloader or hot-
gas by-pass.
- Relatively low rotation velocities and safe operation.
- Simplicity of construction and relative ease of maintenance and repair.
- Relatively low initial cost.
- Capacity control is in steps and the hot-gas by-pass method is a wastage of
compressor input.
- Reliable, spare parts readily available.
- Relatively noisy and lower efficiency.

When the motor, compressor and condenser are completely mounted on the same
frame and they are located remotely from the expansion valve and evaporator, they
form the “Condensing Unit”.

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1.2 Rotary Vane Compressors

Rotory compressor operate with a circular, or rotary, motion instead of reciprocating

motion. Their positive-displacement compression process is non-reversing and either
continuous or cyclical, depending on the type of mechanism. Most are direct
machines. The use of suction valve is not required in vane compressors. The suction
gas enters continuously and so gas pulsation is at a minimum.

1.2.1 Rolling-piston or Single-vane Compressor

A spring-loaded divider separates the suction and the discharge chambers.
The rotor is located eccentrically on the shaft. When it revolves, it makes
contact with the cylinder and compresses the gas.

Figure 2 Rolling–piston Rotary Compressor

1.2.2 Multiple-vane Compressor

The rotor has 2 or more sliding vanes, which are held against the cylinder by
centrifugal force.

(a) 2-vane (b) 4-vane

Figure 3 Multiple-vane Compressor

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The displacement rate D of a rolling position compressor is given by

π
D= 4
( A 2 − B2 )LN (1)

where A = cylinder diameter, m

B = roller diameter, m
L = cylinder length, m
N = rotating speed, revolution per second

Key features of rotary vane compressors:

- R22, R502 & R717 are used in rotary vane compressor
- Up to 4TR for commercial use, up to 150TR for industry application
- Relatively quiet.
- Rolling piston compressor are used in window A/C unit up to 3 hp.
- Capacity control is by on/off mode.

1.3 Rotary Screw Compressors

Single-screw and twin-screw compressors are two distinct types used in refrigeration
and air-conditioning applications. Refrigerant vapour enters one end of the
compressor housing at the top and leaves the other end at the bottom. Figure 4 shows
a cross-sectional view of the 2 principal rotating elements: the screws, where the male
rotor drives the female rotor. The rotation results in meshing of the male lobe with the
female gully, gradually decreases the volume in the cavity and hence compresses the
gas as it travels along the length of the screws. At a certain point the discharge port is
uncovered and the compressed gas is discharged by further meshing of the lobe and
the gully.
- Operate at pressure ratios above 20:1 single stage.
- Capacity range from 70 to 4600kW.
- High isentropic and volumetric efficiencies.
- Relatively quiet.

Figure 4 Cross-section of the screw compressor rotors

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1.3.1 Single Screw Compressor

Figure 5 Cross-section of a Single Screw Compressor

Sequence of compression process:

(a) Suction: During rotation of the main rotor, a typical groove in open
communication with the suction chamber gradually fills with suction gas. The
tooth of the gaterotor in mesh with the groove acts as an aspirating piston.
(b) Compression: As the main rotor turns, the groove engages a tooth on the gaterotor
and is covered simultaneously by the cylindrical main rotor casing. The gas is
trapped in the space formed by the three sides of the groove, the casing, and the
gaterotor tooth. As rotation continues, the groove volume decreases and
compression occurs.
(c) Discharge: At the geometrically fixed point where the leading edge of the groove
and the edge of the discharge port coincide, compression ceases, and the gas
discharges into the delivery line until the groove volume has been reduced to zero.

(a) suction (b) compression (c) discharge

Figure 6 Sequence of Compression Process in Single-Screw Compressor

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1.3.2 Twin Screw Compressor

Twin screw is the common designation for double helical rotary screw compressors.
The twin screw compressor consists of two mating helically grooved rotors - male
(lobes) and female (flutes or gullies) - in a stationary housing with inlet and outlet gas
ports [Figure 7(a)].
- 50-1500 TR capacity
- R22, R134a & R717 can be used
- Capacity control by moving the sliding valve towards the discharge end.
- Capacity control can be continuous / stepless.
- Relatively quiet.

Compression process of twin screw compressor is shown in Figure 7.

(b)Twin Screw Compression Process

(a) Twin Screw Compressor

Figure 7 Twin Screw Compressors

1.4 Scroll Compressors

Scroll compressors are orbital motion, positive

displacement machines that compress with 2
interfitting, spiral-shaped scroll members of phase
difference of 180o. The characteristics include:
- R22
- Small numbers of component.
- Capacity ranging from 3 to 50kW.
- High compression ratio.
- High efficiency and low noise.
- Most suitable for heat pump and air-cooled units
application.
- COP in the range of 3.1 to 3.34.

Capacity control:
- by on/off mode;
- by variable speed scroll compressor; or
- by variable displacement scroll compreesor.
Figure 8
Figure 8 shows the sequence of suction, compression Scroll Compression Process
and discharge phases.

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2. Non-positive Displacement Compressors – Centrifugal

The only type of non-positive displacement compressor which is widely adopted in

the HVAC field is the centrifugal compressor. The increase in pressure of refrigerant
vapour by a continuous transfer of angular momentum from the rotating member to
the refrigerant vapour followed by the conversion of this momentum into a pressure
rise.

Figure 9 Cross Section of a Centrifugal Compressor

The construction is similar to a centrifugal pump. The incoming fluid enters the eye of
the spinning impeller and is thrown by centrifugal force to the periphery of the
impeller. From the impeller the gas flows either into the diffuser blades or into a
volute, where some of the kinetic energy is converted into pressure head (Figure 10).
The flows are continuous, turbomachines have greater volumetric capacities, size for
size, than the positive displacement devices do. For effective momentum exchange,
their rotative speeds must be higher, but little vibration or wear results because of the
steadiness of the motion and the absence of contacting parts.

Figure 10 Impeller Exit Velocity Diagram

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They are multi-stage in general, as many as 8 or 9 stages can be installed in a single

casing and the adiabatic compressor efficiency can reach 70 to 80%. Almost any
refrigerant can be used.

2.1 Characteristics of Centrifugal Compressor

The characteristics of centrifugal compressor include:

- Compression ratio can be increased by connecting impellers in series (multi-stage).
- Range from 200 to 5000TR or even 10000TR, high voltage - 11kV input can be
specified for 1000TR machine and above.
- Refrigerant can be R22, R134a & R717.
- R123 is currently replacing R11 but it has greenhouse effect problem.
- Stepless capacity control by inlet guide vane, variable speed turbine drive,
adjustable frequency controller, combination of vane and speed control.
- Higher volume flow rate than the positive displacement compressor to suit large
capacity application.
- Higher initial cost.
- Higher efficiency.

2.2 Advantages of Centrifugal Machines

The advantages of centrifugal refrigeration machines above 500TR include:

- Flexible under varying load condition.
- Adaptable to a wide range of operating temperature.
- Fewer moving parts than large multi-cylinder reciprocating machines.
- Simplicity of the lubrication system.
- Reasonably good efficiency at part load less than 40% of the design capacity.

Screw, centrifugal and vane compressors are rotary machines.

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2.3 Comparison of Differernt Compressors

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3. Performance

The 2 most important performance indicators in compressors are the refrigeration

capacity and the power requirement. These are mainly controlled by the suction and
discharge pressures of the compressor when it runs at a constant speed. The effects of
these 2 pressures can be visualized through the following analysis.

3.1 Volumetric Efficiency (ηv)

volume flow rate entering compressor

ηv = (2)
displacement rate of compressor

where the displacement rate is the volume swept through by the pistons in their
suction strokes per unit time.

There are 2 volumetric efficiency terms: “clearance” and “actual”. The clearance
volumetric efficiency ηvc depends on the re-expansion of gas trapped in the clearance
volume. See the pressure-volume diagram in Figure 11. If Vc is the clearance volume
(minimum volume) and V3 is the maximum volume of the cylinder, then a term called
percent clearance (m) is defined as:

Vc
m= x100% (3)
V3 − Vc

Figure 11 Pressure-volume Diagram of Reciprocating Compressor

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The amount of gas drawn into the cylinder depends on the instantaneous suction
pressure.

At a suction pressure P1,

V3 − V1
ηvc = x100% (4)
V3 − Vc
Re-arranging equation (4) gives

⎛V ⎞
ηvc = 100 − m⎜ 1 − 1⎟ (5)
⎝ Vc ⎠

V1 v suc
Since = , where v represents the specific volume, therefore for isentropic
Vc v dis
expansion between Vc and V1,

⎛v ⎞
ηvc = 100 − m⎜ suc − 1⎟ (6)
⎝ v dis ⎠

For the extreme case when suction pressure = P3, then ηvc = 0 .

The actual volumetric efficiency ηva is less than ηvc owing to the following
occurrences:
i) pressure drop across valves,
ii) refrigerant leakage, and
iii) suction gas being warmed and expanded in cylinder before the compression.

3.2 Compressor Efficiency ηc

isentropic work of compression

ηc = (7)
actual work of compression

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TUTORIAL

A R-22 refrigeration system operates with an evaporating temperature of 5oC and a

condensing temperature of 50oC. The vapour compression cycle is with 3oC liquid sub-
cooling and 8oC superheating of suction gas. The 6-cyclinder compressor runs at 29 rev/s.
The required power input is 28.9 kW and the refrigerating capacity is 96.4 kW.

Determine:
(a) clearances volumetric efficiency if m= 4.8%,
(b) actual volumetric efficiency, and
(c) compressor efficiency.

Given: for all cylinders, stroke = 57 mm, bore = 67mm.

Solution:
T1 = 5 + 8 = 13oC
T3 = 50 - 3 + 47oC
From R-22 tables

Suction h1 = 413.1 kJ/kg h1= 410 + (414.542-410.851) x (13-10) / (15-10)

v1 = 42.1 l/kg v1= 41.4580+(42.5379-41.458) x (13-10)/(15-10)
s1 = 1.7656 kJ/kg s1= 1.7578 + (1.7708-1.7578) x (13-10)/15-10)
s2 = 1.7656 kJ/kg
Discharge h2 = 444.5 kJ/kg h2 = 442.258 + (446.828 – 442.258) x (1.7656-1.7593)/ (1.7723-
(s1 = s2) 1.7593)
v2 = 14.13 l/kg v2=13.9342 + (14.3325-13.9342) x (1.7656-1.7593)/ (1.7723-
1.7593)
h4 = 259.1 kJ/kg (= hf at
47oC)

⎡v ⎤
(a) η vc = 100 − m ⎢ suc − 1⎥
⎣ v dis ⎦

⎡ 42.1 ⎤
= 100 − 4.8⎢ − 1⎥
⎣14.13 ⎦
= 90.5%

(b) Compressor displacement

⎛ πD 2 ⎞
= (No. of Cylinder) x (Rotat. Speed) x ⎜⎜ L ⎟⎟
⎝ 4 ⎠
= 6 x 29 x π/4 (0.067)2 x 0.057

= 0.03497 m3/s or 34.97 l/s

Actual refrigerant mass flow rate (m)

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Q 96.4kW
= = = 0.626kg / s
h 1 − h 4 (413.1 − 259.1)kJ / kg

Actual volume flow rate at compressor suction

mv1 = 0.626 x 42.1 = 26.35 l/s

26.35
∴ η va = x100 = 75.4%
34.97

(c) Actual work of compression

28.9kW
= = 46.2kJ / kg
0.626kg / s
444.5 − 413.1
∴ ηc = x100 = 68%
46.2

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